Maughan Engineering Consultants

1. CHAPTER 1 - INTRODUCTION................................................................................................... 1-1

1.1 PURPOSE AND OBJECTIVES OF THIS BOOK ................................................................................... 1-1
1.2 MAINTENANCE INFORMATION SOURCES ...................................................................................... 1-1
1.3 DOCUMENT SCOPE AND FOCUS .................................................................................................... 1-2
1.4 UPDATES OF TEXT........................................................................................................................ 1-3
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1. Chapter 1 - Introduction
1.1 Purpose and Objectives of This Book
Beginning in the mid-1970s there was a general contraction in the amount and quality of technical
support provided to power-generation companies by the original equipment manufacturers
(OEMs). This void has been partially filled by independent service providers. But often, owners
have been left uncertain as to the quality and accuracy of the available information.
The purpose of this book is to provide a maintenance manual which will help turbine-generator
users remove some of these uncertainties, and thereby work more effectively and efficiently with
their service providers in maintaining high reliability of their generators.
The text is written from a manufacturer perspective, based on an experience background in factory
generator design, manufacturing and service, as well as field service.
Focus of the text will intentionally be somewhat narrow, with the intent of including only
information directly relating to making optimum maintenance decisions.
For operating companies with strong in-house generator maintenance capability and programs, it
is hoped that this text will be of assistance in improving and fine-tuning those programs.
For operating companies depending primarily on outside technical sources, it is hoped this text
will assist in appraising the quality and accuracy of maintenance recommendations.
In both cases, it is hoped that this book will assist owners in implementing more cost-effective
maintenance programs for each of their power generators.
1.2 Maintenance Information Sources
Historically, turbine-generator OEMs gave a high level of support to users of their equipment. In
addition to a competent staff of factory engineers available for consultation on specific issues, in
particular root-cause diagnosis of new and difficult equipment failures, OEMs traditionally have
issued three types of maintenance recommendations:
Instruction Books covering routine assembly and general maintenance of individual
units,
Technical information letters addressing specific maintenance problems on groups or
classes of units, and
Individual letters on specific units.
Further, manufacturers have typically supplied technical assistance and on-site specialized
Inspection, Test, and Maintenance services through a fleet of trained and experienced field
engineers.
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Additional support has been available to users through:
Professional groups such as IEEE and ASME, although unfortunately OEM technical
input to these organizations has greatly decreased, with little OEM input to technical
conferences and few industry papers being published by OEMs.
Industry organizations such as EPRI and ANSI, which continue to provide vital services.
Articles and books published by utility personnel documenting best practice experience
of user companies.
Independent service providers, including independent technical consultants.
It is vital to understand that the field engineers available from OEMs and independent service
providers typically are trained in inspection, test and maintenance. But typically they are not
trained and qualified to perform the difficult challenges of root-cause diagnostics. Historically this
service was provided by OEM factory engineers; however, with the contraction of OEM
engineering organizations, OEM engineers qualified for diagnostics are no longer readily
available for filling this vital need. As a result, it may be very difficult to find personnel capable
of accurately diagnosing a new or unusual failure mechanism. This situation is increasingly
leading to incorrect and often costly maintenance decisions. It appears that the challenge to plant
personnel in dealing with this condition will remain high for some time to come.
1.3 Document Scope and Focus
The text will focus primarily on the generator, although some attention is given to auxiliaries and
excitation systems.
Heavy use is made of illustrations and photographs, and color is used throughout where helpful.
Subjects covered will include:
a) Chapter 2. Impact of generator design on component duties and deterioration
mechanisms.
b) Chapter 3. Impact of normal and abnormal operation on deterioration modes and
rates.
c) Chapter 4. Description of failure modes.
d) Chapter 5. On-line monitoring and failure root-cause diagnostics.
e) Chapter 6. Inspection procedures and equipment.
f) Chapter 7. Test procedures and equipment.
g) Chapter 8. Maintenance practices and general principles, including predictive and
condition-based maintenance.
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1.4 Text Updates
Because this book is in digital format, revision is conveniently accomplished, and the text has
been updated several times since first written in 1997. The current revision, June 2005, includes
significant additions in two important areas:
The severe technical-personnel problems associated with obtaining accurate root-cause
diagnostics are now discussed. Chapter 5, Section 5.3.
Some of the special operations/maintenance issues associated with collectors and brush
holder rigging are addressed. Chapters 2, Section 2.2.7, Chapter 3, Section 3.2.18,
Chapter 8, Section 8.3.3.2.